Airframe Crown Module Assembly in Continuous Fuselage Lines

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Solution Overview

Problem

Current aircraft assembly methods require significant space and time due to the need for tools and technicians to enter barrel sections through doorways, leading to inefficiencies in the fabrication and installation of airframe components, particularly in the assembly of crown modules within the fuselage.

Innovation Solution

The implementation of continuous line assembly layouts and systems that allow airframe components to be moved continuously through workstations, with components being installed just-in-time at specific stations along a track, reducing the need for tools and technicians to enter confined spaces and enabling simultaneous work on multiple parts during pauses or pulses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If tools and technicians enter barrel sections through doorways for assembly work, then access to work areas is achieved, but assembly time and downtime increase significantly

Engineering Contradiction:

Improveaccess to work areaVSAvoidassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The fuselage is divided into multiple barrel sections that can be independently positioned and assembled. This segmentation allows tools and components to be accessed from external locations rather than requiring entry through doorways, significantly reducing assembly time while maintaining ease of access to work areas.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of bringing tools and technicians into the barrel section through doorways, the invention inverts the approach by positioning barrel sections and components externally and bringing them together at assembly points. This reversal eliminates the need for entry/exit operations and reduces downtime.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If tools and equipment are set up inside barrel sections, then work can be performed on the structure, but the process requires repeated setup and transport operations

Engineering Contradiction:

Improvework capabilityVSAvoidthroughput

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Barrel sections and components are prepared and pre-assembled outside the fuselage before being positioned into their final locations. This preliminary action eliminates the need for repeated setup and transport operations inside the barrel sections, maintaining work capability while significantly improving throughput and productivity.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If crown modules are assembled inside the fuselage, then installation is achieved, but space requirements and assembly complexity increase

Engineering Contradiction:

Improveinstallation capabilityVSAvoidfactory space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The crown module assembly process is segmented into external preparation stages and final installation stages. Components are assembled in modular sections outside the fuselage where space is not constrained, then these pre-assembled modules are installed into the fuselage. This maintains installation capability while dramatically reducing the factory space required for the assembly process.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12252271B2Methods and systems for assembly and installation of airframe crown modules

Publication Date: 2025.03.18 THE BOEING CO

AI summary

Systems and methods are provided for assembling an aircraft. The method includes receiving an upper half barrel section of fuselage that is in a crown up orientation and installing a crown module into the upper half barrel section.